Introduction to Sensors Industry 4.0 with Human Touch, Technology course By Fjodor van Slooten
CONTENT Introduction to Sensors • Introduction to ‘Sense’ • Sensor types • Industrial Sensors • Application in production environments/factories • Industry 4.0 • Practical (2 nd part of day) This presentation & tutorials available at: Contact: f.vanslooten@utwente.nl vanslooten.com/i40 or via Canvas 11/27/2019 Introduction to Sensors - Industry 4.0 with Human Touch 2
‘SENSE’ • Why? • Need to know something (of your environment) • What? • In industry: measure process ‘sensor’ detects carbon monoxide 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 3
Five Senses of Sensors (human/biology) Sound, Vision, Taste, Smell, and Touch There are more: e.g. balance & acceleration, temperature, proprioception , pain, … wikipedia.org/wiki/Sense 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 4
Machine Sensors “… a sensor is a device, module, machine, or subsystem whose purpose is to detect events or changes in its environment and send the information to other electronics, frequently a computer processor…” wikipedia.org/wiki/Sensor ▪ Electromagnetic spectrum (frequency spectrum): radio, sound, light ▪ Chemical: sense chemical compounds, capacitive ▪ Mechanical: touch, rotate, bend, accelerate... ▪ Combined (smart): include processor, eg. ultrasonic sensor: calculates distance 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 5
‘Sense’ - conclusion ▪ There are infinite types of sensors and lots of senses (types). ▪ This lecture is only an introduction : you will have to do research for your own application/assignment! www.spectralengines.com/articles/industry-4-0-and-how-smart-sensors-make-the-difference The Five Senses of Sensors — Part I: Smell, Taste, and Hearing The Five Senses of Sensors — Part II: Touch and Vision How Sensors Make Sense The Evolution of Sensors: Canaries to Drones Industry 4.0 and how smart sensors make the difference 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 6
Focus SENSOR TYPES Industrial, Professional, Consumer 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 7 blackboxparadox.com/2016/12/19/iot-sensor-classification
Examples: conveyor belts Monitoring conveyor belt speed Quality and position monitoring on conveyor belts Belt speed is In order to grip objects on moving conveyor belts, a pick- controlled using the and-place robot requires an image processing system that measured values of a gives it the ability to “see.” A programmable 3D vision programmable sensor is a reliable solution under difficult conditions. incremental encoder. 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 8
Photoelectric distance sensor Product page W16 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 9
How does a photoelectric sensor work? Through-beam Sensors Retro-reflective Sensors Ultrasonic sensors use same principle, but use (ultrasonic) sound instead of Diffuse-reflective Sensors light Read more @ Omron website 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 10
Clear Object Detection ▪ Special variant of the standard, retroreflective sensor ▪ Amount of light that returns is slightly less ▪ Sensor must be sensitive Learn more blog.pepperl-fuchs.us/blog/bid/250978/Clear-Object-Detection-with-Photoelectric-Sensors 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 11
INDUSTRIAL SENSORS • Proximity sensors • Photoelectric sensors • Ultrasonic sensors • Rotary encoders • Positioning systems • Inclination and acceleration sensors • Identification systems • Vision sensors • More… 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 12 Images courtesy of Keyence
Manufacturers Sensor basics & selection Products & intro to technologies Product portfolio & know-how More... 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 13 Images courtesy of Sick, Pepperl+Fuchs
Choosing sensors • Scenarios: when to apply what? (choosing type of sensors) • What do sensors actually do/measure? • What properties do they have? Sensor basics & selection • Sample-speed: if you use a slow sensor on a high-speed conveyor belt... • If sensor uses light(-beam) can this be used on glass- products? (eg. bottles) Products & intro to technologies • What could possibly go wrong? • Errors in measurements... how to prevent? • Validity • Reliability Product portfolio & know-how 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 14
Selection criteria: when to use … • Accuracy (error between result and actual value) • Repeatability/precision (ability to repeat same values for same input over a number of trials) • Stability Environmental condition Cost • Sensitivity Power (consumption) Connectivity • Range (highest/lowest values) Integration Standards • Resolution (smallest increment of measure) … • Calibration TechTip: Accuracy, Precision, Resolution, and Sensitivity 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 15
Accuracy vs. Resolution 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 16
Accuracy vs. Precision 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 17
Rules of thumb when selecting 1. Narrow sensor candidates. What is the color, shape and material of the target? 2. How close can you get to the target? For close-range applications, use inductive or capacitive sensors. Otherwise, photoelectric or ultrasonic sensors are better. 3. What is the available voltage supply? Specify whether sensor will be AC or DC. 4. What will be near the sensor face? If materials are very close, choose flush or non-flush mounted inductive or capacitive sensors. 5. Consider the background's distance, color, shape, and material. Can anything be mounted here? Is background suppression photoelectric sensing needed, or can the background serve as reflector for retroreflective ultrasonic sensing? Close backgrounds can interfere with inductive or capacitive sensors. 6. For reliable detection, at what speed and frequency do targets pass the sensor? 7. Sensor output styles vary. Do you need an output when the target is present? 8. What is the electrical load you plan to place on the sensor's output powers? A PNP or NPN interface might be required for large loads. 9. Asses the cleanliness, temperature and moisture of the sensor environment and from that determine the appropriate environmental rating. 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 18
Read more Sensor Basics: Introductory Guide to Sensors 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 19
APPLICATION in production environments/factories www.spectralengines.com/articles/industry-4-0-and-how-smart-sensors-make-the-difference 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 20
Areas of Application: Industries 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 21 Images courtesy of Pepperl+Fuchs
Application of Proximity sensors [measure if an object is near] ▪ Inductive ▪ Capacitive ▪ Magnetic Field Detecting metal objects Positioning machine parts (Valve positioning, On/off switches) Speed monitoring 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 22 Images courtesy of Pepperl+Fuchs
Application of Photoelectric Sensors [distance] Automotive Material Handling Machine Engineering Pepperl+Fuchs Blog: 5 Applications for Food and Beverage Photoelectric Sensors Doors, Gates, and Elevators 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 23 Images courtesy of Pepperl+Fuchs
Application of Ultrasonic Sensors [distance] Detecting packaging material: end of roll Independent of material: plastic/paper, transparent/colored, black/white Measuring distance: avoiding Level measurement collisions Bottle Counting With Ultrasonic Sensors 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 24 Images courtesy of Pepperl+Fuchs
Application of Rotary Encoders [degrees/angle/rotations/speed] Speed monitoring Distance measurement Angle measurement Conveyor belt speed monitoring Propeller angle Speed monitoring of generator Angle z-axis 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 25 Images courtesy of Pepperl+Fuchs
Application of Positioning systems [location/position] Absolute positioning (data-matrix code) Navigation Absolute positioning Navigation 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 26 Images courtesy of Pepperl+Fuchs
Inclination & acceleration sensors [degrees, acceleration in 1 or more directions, axis] Container spreader angle measurement Using the data of the inclination sensor, the steering angle can be limited to prevent tilting 27/11/2019 Introduction to Sensors - Industry 4.0 with Human Touch 27 Images courtesy of Pepperl+Fuchs
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